U.S. patent application number 15/367411 was filed with the patent office on 2017-06-08 for building framing system.
The applicant listed for this patent is CLEMSON UNIVERSITY. Invention is credited to Dustin Graham Albright, Eric Balogh, Allyson Beck, Vincent Yves-Marie Blouin, Amelia Brackmann, Russell Buchanan, Clair Dias, Ufuk Ersoy, Jeff Hammer, Justin Hamrick, Daniel Nevin Harding, Ulrike Ann-Sophie Heine, David Herrero, Will Hinkley, Alexandra Latham, Neely Leslie, Alex Libengood, Alison Martin, Ty Monks, Paul Mosher, David Aaron Pastre, Jon Pennington, Tyler Silvers, Michael Stoner, Rodney Daniel Taylor, II, Rebecca Mercer Wilson, Anthony Wohlers.
Application Number | 20170159290 15/367411 |
Document ID | / |
Family ID | 58799776 |
Filed Date | 2017-06-08 |
United States Patent
Application |
20170159290 |
Kind Code |
A1 |
Albright; Dustin Graham ; et
al. |
June 8, 2017 |
BUILDING FRAMING SYSTEM
Abstract
A building framing system includes a floor portion or floor
framing system, a wall portion or wall framing system, and a roof
portion or roof framing system. Each framing system comprises a
plurality of components. Each component defines a connection
geometry for connecting one component to another. The connection
geometries are such that mechanical or other similar fasteners are
not required to hold the various components together; rather, the
connection geometries connect the components and hold them in place
with respect to one another. Further, the framing systems utilize
pre-cut components such that the components of each framing system
arrive onsite cut to a needed length and width and with the
appropriate connection geometry.
Inventors: |
Albright; Dustin Graham;
(Clemson, SC) ; Blouin; Vincent Yves-Marie;
(Central, SC) ; Harding; Daniel Nevin; (Clemson,
SC) ; Pastre; David Aaron; (Charleston, SC) ;
Heine; Ulrike Ann-Sophie; (Pendleton, SC) ; Ersoy;
Ufuk; (Central, SC) ; Monks; Ty; (Bozeman,
MT) ; Wohlers; Anthony; (Greenville, SC) ;
Stoner; Michael; (Aiken, SC) ; Balogh; Eric;
(Atlanta, GA) ; Silvers; Tyler; (Clemson, SC)
; Dias; Clair; (Winston-Salem, NC) ; Martin;
Alison; (Clemson, SC) ; Pennington; Jon;
(Clemson, SC) ; Hammer; Jeff; (Nashville, TN)
; Hinkley; Will; (Greenville, SC) ; Hamrick;
Justin; (Shelby, NC) ; Latham; Alexandra;
(Sumter, SC) ; Leslie; Neely; (Brooklyn, NY)
; Taylor, II; Rodney Daniel; (York, SC) ; Herrero;
David; (Greenville, SC) ; Wilson; Rebecca Mercer;
(Anderson, SC) ; Buchanan; Russell; (Clemson,
SC) ; Brackmann; Amelia; (Stafford, VA) ;
Mosher; Paul; (Clemson, SC) ; Beck; Allyson;
(Clemson, SC) ; Libengood; Alex; (Charleston,
SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CLEMSON UNIVERSITY |
Clemson |
SC |
US |
|
|
Family ID: |
58799776 |
Appl. No.: |
15/367411 |
Filed: |
December 2, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62262576 |
Dec 3, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16B 7/22 20130101; E04B
2001/2692 20130101; F16B 5/07 20130101; E04B 2001/2664 20130101;
E04B 5/14 20130101; E04B 1/26 20130101; E04B 2001/2672 20130101;
F16B 3/00 20130101; E04B 2001/262 20130101; E04B 2/707 20130101;
E04B 2001/2624 20130101; E04B 2001/2696 20130101; E04B 5/023
20130101 |
International
Class: |
E04B 5/02 20060101
E04B005/02; E04B 7/02 20060101 E04B007/02; E04B 5/10 20060101
E04B005/10; E04B 7/20 20060101 E04B007/20; E04B 1/343 20060101
E04B001/343; E04B 5/12 20060101 E04B005/12 |
Goverment Interests
FEDERAL RESEARCH STATEMENT
[0002] This invention was made with government support under grant
#DE-EE0006559 awarded by The Department of Energy. The government
has certain rights in the invention.
Claims
1. A building framing system, comprising: a floor portion including
a plurality of floor joist components, each floor joist component
having a projection, and a plurality of subfloor components, each
subfloor component defining a recess, wherein at least one subfloor
component is adjacent a floor joist component such that the
projection of the adjacent floor joist component fits within the
recess of the subfloor component; a wall portion including a
plurality of wall web components, each wall web component having a
projection, and a plurality of wall flange components, each wall
flange component defining a recess, wherein at least one wall
flange component is adjacent a wall web component such that the
projection of the adjacent wall web component fits within the
recess of the wall flange component; and a roof portion including a
plurality of roof web components, each roof web component having a
projection, and a plurality of roof flange components, each roof
flange component defining a recess, wherein at least one roof
flange component is adjacent a roof web component such that the
projection of the adjacent roof web component fits within the
recess of the roof flange component.
2. The building framing system of claim 1, further comprising a
plurality of tie components, wherein each tie component is
positioned within a hole defined in a wall web component and a hole
defined in a wall flange component, and wherein each tie component
is fastened together to hold a wall web component and a wall flange
component in place with respect to one another during assembly of
the building framing system.
3. The building framing system of claim 2, wherein each tie
component is a metal zip tie fastener.
4. A building framing system, comprising: a plurality of first
components, each of the first components defining a first
connection geometry; and a plurality of second components, each of
the second components defining a second connection geometry,
wherein the first connection geometry joins with the second
connection geometry to connect adjacent first and second components
such that mechanical fasteners are not required to attach a first
component to an adjacent second component.
5. The building framing system of claim 4, wherein the first
connection geometry is pre-cut into each first component, and
wherein the second connection geometry is pre-cut into each second
component.
6. The building framing system of claim 4, wherein the first
components and the second components are cut from at least one
sheet of a building material.
7. The building framing system of claim 6, wherein the building
material is structural plywood.
8. The building framing system of claim 4, further comprising a
plurality of tie components, wherein each tie component is
positioned within a notch defined in a first component and a notch
defined in a second component, and wherein each tie component is
fastened together to hold the first component and the second
component in place with respect to one another during assembly of
the building framing system.
9. The building framing system of claim 8, wherein each tie
component is a metal zip tie fastener.
10. The building framing system of claim 4, further comprising a
plurality of tie components, wherein each tie component is
positioned within a hole defined in a first component and a hole
defined in a second component, and wherein each tie component is
fastened together to hold the first component and the second
component in place with respect to one another during assembly of
the building framing system.
11. The building framing system of claim 10, wherein each tie
component is a metal zip tie fastener.
12. The building framing system of claim 4, wherein the first
components are web components the first connection geometry is a
projection, and wherein the second components are flange components
and the second connection geometry is a recess.
13. The building framing system of claim 4, wherein the first
components are floor joists and the first connection geometry is a
slot, and wherein the second components are floor leveling joists
and the second connection geometry is a portion of the second
component perpendicular to the first component.
14. The building framing system of claim 4, wherein the first
components are floor joists and the first connection geometry is a
projection, and wherein the second components are subfloor
components and the second connection geometry is a recess.
15. The building framing system of claim 4, wherein the first
components are floor joists and the second components are floor
noggings, and wherein and the first connection geometry is a
portion of floor joists perpendicular to floor noggings and the
second connection geometry is a double notch.
16. The building framing system of claim 4, wherein the first
components are roof web components and the first connection
geometry is a half S-joint, and wherein the second components are
roof web components and the second connection geometry is a half
S-joint.
17. The building framing system of claim 4, wherein the first
components are wall web components and the first connection
geometry is a half Z-joint, and wherein the second components are
wall web components and the second connection geometry is a half
Z-joint.
18. The building framing system of claim 4, wherein the first
components are wall web components and the second components are
floor end joist components, and wherein the first and the second
connection geometries are rounded to facilitate tilting the wall
web components into place with respect to the floor end joists.
19. The building framing system of claim 4, wherein the first
components are wall flange components and the first connection
geometry is a rounded tab, and wherein the second components are
floor rim joist components and the second connection geometry is a
cut-out corresponding to the rounded tab.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional
Application Ser. No. 62/262,576, filed on Dec. 3, 2015, which is
incorporated herein in its entirety by reference thereto.
FIELD OF THE INVENTION
[0003] The present invention generally involves a system for
framing buildings. In particular embodiments, the system may
comprise a floor portion, a wall portion, and a roof portion. In
other embodiments, a floor framing system, a wall framing system,
and a roof framing system may be provided.
BACKGROUND OF THE INVENTION
[0004] For many years, light wood framing has been a dominant
construction technique for small structures, such as detached
housing and the like. Typical building framing systems utilize
dimensional lumber and standard mechanical fasteners such as nails
and screws. Light wood framing techniques usually involve cutting
the lumber onsite to needed sizes, which requires cutting tools and
often requires a certain amount of skill. Further, assembling a
light wood frame generally requires lifting heavy wall sections
into place, which then must be braced, and roofs of light wood
frames may require large trusses that must be set in place by using
a machine lift. Moreover, light wood framing typically requires the
use of mechanical or other similar fasteners to connect the various
components of the frame. As such, the fasteners and tools for
fastening the fasteners, such as hammers, nail guns, and the like,
must be provided. Each of these conditions can increase the
cost--including materials and labor--of construction and decrease
the safety of the construction site.
[0005] Accordingly, a need exists for an improved building framing
system that may overcome one or more disadvantages of existing
systems. For example, an improved system may comprise three
portions or systems including components that connect or attach to
one another using certain geometries rather than mechanical
fasteners. Alternately, or in addition, an improved system may
utilize pre-cut components such that the components of the framing
system arrive onsite cut to a needed length and width and with the
appropriate connection geometry.
BRIEF DESCRIPTION OF THE INVENTION
[0006] Aspects and advantages of the invention are set forth below
in the following description, or may be obvious from the
description, or may be learned through practice of the
invention.
[0007] In one aspect, the present subject matter is directed to a
building framing system. The building framing system comprises a
plurality of first components, each of the first components
defining a first connection geometry; and a plurality of second
components, each of the second components defining a second
connection geometry. The first connection geometry joins with the
second connection geometry to connect adjacent first and second
components such that mechanical fasteners are not required to
attach a first component to an adjacent second component.
[0008] In another aspect, the present subject matter is directed to
a building framing system. The building framing system comprises a
floor portion, a wall portion, and a roof portion. The floor
portion includes a plurality of floor joist components and a
plurality of subfloor components. Each floor joist component has a
projection, and each subfloor component defines a recess. At least
one subfloor component is adjacent a floor joist component such
that the projection of the adjacent floor joist component fits
within the recess of the subfloor component. The wall portion
includes a plurality of wall web components and a plurality of wall
flange components. Each wall web component has a projection, and
each wall flange component defines a recess. At least one wall
flange component is adjacent a wall web component such that the
projection of the adjacent wall web component fits within the
recess of the wall flange component. The roof portion includes a
plurality of roof web components and a plurality of roof flange
components. Each roof web component has a projection, and each roof
flange component defines a recess. At least one roof flange
component is adjacent a roof web component such that the projection
of the adjacent roof web component fits within the recess of the
roof flange component.
[0009] Those of ordinary skill in the art will better appreciate
the features and aspects of such embodiments, and others, upon
review of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A full and enabling disclosure of the present invention,
including the best mode thereof to one skilled in the art, is set
forth more particularly in the remainder of the specification,
including reference to the accompanying figures, in which:
[0011] FIG. 1 is a perspective view of a building framing system
according to an exemplary embodiment of the present subject
matter.
[0012] FIG. 2 is a schematic view of a building framing system
according to another embodiment of the present subject matter.
[0013] FIG. 3 is a perspective view of a portion of a wall framing
system according to an exemplary embodiment of the present subject
matter.
[0014] FIG. 4 is a side perspective view of the portion of the wall
framing system of FIG. 3.
[0015] FIG. 5 is an illustration of a wall web component of a wall
framing system according to an exemplary embodiment of the present
subject matter.
[0016] FIG. 6 is an illustration of a wall flange component of a
wall framing system according to an exemplary embodiment of the
present subject matter.
[0017] FIG. 7A is an illustration of a wall stud of a wall framing
system according to an exemplary embodiment of the present subject
matter.
[0018] FIG. 7B is an illustration of a use of an outer wall flange
of a wall framing system according to an exemplary embodiment of
the present subject matter.
[0019] FIG. 8A is an illustration of floor joist components of a
floor framing system according to an exemplary embodiment of the
present subject matter.
[0020] FIG. 8B is an illustration of a subfloor components of a
floor framing system according to an exemplary embodiment of the
present subject matter.
[0021] FIG. 9 is an illustration of roof web components and roof
flange components of a roof framing system according to an
exemplary embodiment of the present subject matter.
[0022] FIG. 10 is an illustration of a roof web component of a roof
framing system according to another exemplary embodiment of the
present subject matter.
[0023] FIG. 11 is an illustration of a roof web component of a roof
framing system according to another exemplary embodiment of the
present subject matter.
[0024] FIG. 12 is an illustration of a mortise and tenon double
field connection according to an exemplary embodiment of the
present subject matter.
[0025] FIG. 13 is an illustration of a mortise and tenon header
connection according to an exemplary embodiment of the present
subject matter.
[0026] FIG. 14 is an illustration of a mortise and tenon standard
edge connection according to an exemplary embodiment of the present
subject matter.
[0027] FIG. 15 is an illustration of a slot connection according to
an exemplary embodiment of the present subject matter.
[0028] FIG. 16 is an illustration of a single notch connection
according to an exemplary embodiment of the present subject
matter.
[0029] FIG. 17 is an illustration of a double notch connection
according to an exemplary embodiment of the present subject
matter.
[0030] FIG. 18 is an illustration of a S-joint connection according
to an exemplary embodiment of the present subject matter.
[0031] FIG. 19 is an illustration of a Z-joint connection according
to an exemplary embodiment of the present subject matter.
[0032] FIG. 20 is an illustration of a tilt-up wall connection
according to an exemplary embodiment of the present subject
matter.
[0033] FIG. 21 is an illustration of a ball joint connection
according to an exemplary embodiment of the present subject
matter.
[0034] FIG. 22 is an illustration of wall flange components
connected to floor rim joist components using the ball joint
connection of FIG. 21.
[0035] FIG. 23 is an illustration of a blunt tooth connection, as
well as the double notch connection of FIG. 17, according to an
exemplary embodiment of the present subject matter.
[0036] FIG. 24 is an illustration of brace members connected to one
another and to a roof component using the blunt tooth connection of
FIG. 23, as well as an illustration of brace member connected to a
wall web component using the double notch connection of FIG.
17.
[0037] FIG. 25 is a further illustration of the brace members
connected to one another and to the wall web component as shown in
FIG. 24.
[0038] FIG. 26 is an illustration of a step joint according to an
exemplary embodiment of the present subject matter.
[0039] FIG. 27 is an illustration of a wall web component connected
to a roof web component using the step joint of FIG. 26 and a
key.
[0040] FIG. 28 is a close-up view of the step joint and key of FIG.
27.
[0041] FIG. 29 is an illustration of a floor joist connection
according to an exemplary embodiment of the present subject
matter.
[0042] FIG. 30 is an illustration of a portion of a floor framing
system according to an exemplary embodiment of the present subject
matter.
[0043] FIG. 31 is an illustration of another portion of a floor
framing system according to an exemplary embodiment of the present
subject matter.
DETAILED DESCRIPTION OF THE INVENTION
[0044] Reference will now be made in detail to present embodiments
of the invention, one or more examples of which are illustrated in
the accompanying drawings. The detailed description uses numerical
and letter designations to refer to features in the drawings. Like
or similar designations in the drawings and description have been
used to refer to like or similar parts of the invention. As used
herein, the terms "first," "second," and "third" may be used
interchangeably to distinguish one component from another and are
not intended to signify location or importance of the individual
components.
[0045] Each example is provided by way of explanation of the
invention, not limitation of the invention. In fact, it will be
apparent to those skilled in the art that modifications and
variations can be made to embodiments of the present invention
without departing from the scope or spirit thereof. For instance,
features illustrated or described as part of one embodiment may be
used on another embodiment to yield a still further embodiment.
Thus, it is intended that the present invention covers such
modifications and variations as come within the scope of the
appended claims and their equivalents.
[0046] Embodiments of the present subject matter include a building
framing system. Various embodiments of the system provide a floor
framing system, a wall framing system, and a roof framing system.
Each framing system comprises a plurality of components, each
component defining a connection geometry for connecting one
component to another. The connection geometries are such that
mechanical or other similar fasteners are not required to hold the
various components together; rather, the connection geometries
connect the components and hold them in place with respect to one
another.
[0047] FIG. 1 provides a perspective view of a building framing
system 10 according to one embodiment of the present invention. As
shown in FIG. 1, building framing system 10 generally includes a
floor portion 100, a wall portion 200, and a roof portion 300. In
alternative embodiments, each portion--floor 100, wall 200, and
roof 300--may comprise a separate system and may be referred to as
floor framing system 100, wall framing system 200, and roof framing
system 300, respectively. Moreover, for ease of reference, each
portion simply may be referred to as floor 100, wall 200, and roof
300, whether the portion is being described as a part of building
framing system 10 or a separate system.
[0048] Further, it will be understood through the description
provided herein that in various embodiments of the present subject
matter, the various portions of building framing system 10 may be
used separately or in various combinations. For example, in one
embodiment, floor 100 and wall 200 may be used together, without
including roof 300. Rather, in such embodiment, a different roof or
roofing system, or no roof or roofing system as appropriate, may be
used with floor 100 and wall 200. As another example, depicted
schematically in FIG. 2, two floor portions or systems 100 and two
wall portions or systems 200 may be used with one roof portion or
system 300. As illustrated in FIG. 2, in such embodiment, floor
portions 100 may be alternated with wall portions 200 along a
vertical direction V, ending with a roof portion 300 as the
vertically uppermost portion of the building framing system 10.
[0049] Referring now to FIGS. 3-22, each portion of building
framing system 10 will be described in greater detail. Referring
particularly to FIGS. 3 through 6, wall 200 includes a plurality of
wall web components 202. Each wall web 202 has at least one
projection 204, which is a first connection geometry. Projections
204 have a defined or particular shape for joining the components
of wall 200, as described herein. Further, wall 200 comprises a
plurality of wall flange components 206. Each wall flange 206
defines at least one recess 208, which is a second connection
geometry. Recesses 208 are configured for receipt of projections
204, i.e., the first connection geometry joins with the second
connection geometry to connect adjacent wall webs 202 and wall
flanges 206. For example, in wall 200 shown in FIG. 3, at least one
wall flange 206 is adjacent a wall web 202 such that a projection
204 of wall web 202 fits within a recess 208 of wall flange
206.
[0050] As shown in FIG. 5, each wall web 202 has a first edge 210
opposite a second edge 212 and a third edge 214 opposite a fourth
edge 216. More particularly, in the depicted embodiment, first edge
210 and second edge 212 are spaced apart along a length direction L
and third edge 214 and fourth edge 216 are spaced apart along a
width direction W. Four projections 204 are defined along third
edge 214 and three projections 204 are defined along fourth edge
216. Moreover, web 202 defines three apertures 218, the apertures
spaced apart from one another along the length direction L. By
removing material to form or define apertures 218, a weight of web
202 can be reduced. Also, apertures 218 provide a space or area
through which other elements of the building can pass, e.g., a
space through which electrical wiring, plumbing, and the like can
be routed. As also depicted in FIG. 5, web 202 defines a plurality
of notches n, each notch n defined adjacent an aperture 218 such
that notches n are spaced apart from edges 210, 212, 214, 216.
Additionally, wall web 202 defines a plane P.sub.ww, such that each
of the foregoing elements of web 202--e.g., edges 210, 212, 214,
216, notches n, apertures 218, and projections 204--lie within or
are parallel to plane P.sub.ww.
[0051] As further shown in the exemplary embodiment of FIG. 6, each
wall flange 206 has a first edge 220 opposite a second edge 222 and
a third edge 224 opposite a fourth edge 226. First edge 220 and
second edge 222 are spaced apart along the length direction L and
third edge 224 and fourth edge 226 are spaced apart along the width
direction W. A plurality of notches n are defined along third edge
224 and fourth edge 226. In the depicted embodiment, flange 206
defines four recesses 208 between edges 220, 222, 224, 226 and one
recess 208 along third edge 224. Moreover, wall flange 206 defines
a plane P.sub.wf, such that each of the foregoing elements of
flange 206--e.g., edges 220, 222, 224, 226, notches n, and recesses
208--lie within or are parallel to plane P.sub.wf.
[0052] Referring to FIG. 7A, wall system 200 is comprised of a
plurality of studs 228. Each stud 228 includes a wall web 202 and
two flanges 206, where one flange 206 is positioned adjacent third
edge 214 of web 202 and the other flange 206 is positioned adjacent
fourth edge 216 of web 202. The plane P.sub.wf defined by each
flange 206 is oriented perpendicularly to plane P.sub.ww defined by
web 202. Accordingly, projections 204 defined along third and
fourth edges 214, 216 of web 202 fit within recesses 208 of flanges
206 to attach web 202 and flange 206. As such, mortise and tenon
joints are formed between attached webs 202 and flanges 206. The
mortise and tenon joints formed by the projection connection
geometry and recess connection geometry do not require mechanical
fasteners to attach the wall webs 202 to adjacent flanges 206.
Further, one of ordinary skill in the art will appreciate that any
appropriate number of projections 204 and recesses 208 may be used
to attach webs 202 and flanges 206.
[0053] As further shown in FIG. 4, a notch n defined in web 202 may
be adjacent or near one or more notches n defined in flanges 206. A
tie component t, such as a cable or zip tie made from a metal such
as steel or the like, may be positioned within adjacent notches n
of web 202 and a flange 206 and then fastened together to hold the
web 202 and respective flange 206 in place with respect to one
another, e.g., such that web 202 and flanges 206 do not slip or the
mortise and tenon joints formed by web 202 and flanges 206 do not
separate during assembly of the building framing system 10,
including as wall 200 is constructed and/or moved into position
with respect to floor 100. In other embodiments, for example as
shown in FIG. 7A, one or more holes h may be used in place of notch
n in web 202 and/or notch n in flange 206. In the embodiment of
FIG. 7A, tie t passes through a hole h in web 202 and is positioned
within notches n in flange 206 and fastened together to hold web
202 and flange 206 in place with respect to each other. Holes h
preferably are spaced inward from edges 210, 212, 214, 216 of web
202 or edges 220, 222, 224, 226 of flange 206, i.e., holes h are
not defined close to an edge of a web 202 or a flange 206. It will
be understood that other configurations of notches n, holes h, and
ties t may be used as well.
[0054] FIG. 7B illustrates one use or purpose of flanges 206. As
previously described with respect to FIG. 7A and as further
depicted in FIG. 4, each stud 228 comprises two flanges 206
oriented perpendicularly to web 202. These flanges may be described
as an interior flange 206a and an exterior flange 206b. As shown in
FIG. 7B, the orientation of flanges 206a and 206b provides a
surface for attaching exterior and interior finish materials, e.g.,
exterior sheathing 230 may be attached to exterior flange 206b
using mechanical fasteners such as screws 232 or other suitable
fasteners. Similarly, interior finish materials, e.g., a suitable
interior wall finish material such as drywall or plywood, may be
attached to interior flange 206a using mechanical or other
appropriate fasteners. As described more particularly below, the
components of wall system 200 preferably are fabricated or made
from structural plywood. Mechanical fasteners inserted through the
edge of plywood can split the plywood or tear out of the plywood.
By providing flanges 206a, 206b substantially parallel to finish
materials such as exterior sheathing 230, mechanical fasteners can
pass through the face of plywood flanges 206a, 206b rather than the
edge of web 202 and thereby limit or reduce splitting the plywood
with the fasteners and/or tearing out of the fasteners.
[0055] Referring now to FIGS. 8A and 8B, floor system 100 similarly
utilizes mortise and tenon connections to attach its various
components to one another. More particularly, floor 100 includes a
plurality of joists 102. Each joist has at least one projection
104, which is a first connection geometry. Further, floor 100
comprises a plurality of subfloor components 106. Each subfloor
component 106 includes at least one recess 108, which is a second
connection geometry. Recesses 108 are configured for receipt of
projections 104, i.e., the first connection geometry joins with the
second connection geometry to connect adjacent floor joists 102 and
subfloor components 106. Further, projections 104 have a defined or
particular shape for joining floor joists 102 and subfloor
components 106. For example, in floor 100, at least one subfloor
component 106 is adjacent a joist 102 such that a projection 104 of
joist 102 fits within a recess 108 of subfloor component 106. As
such, joists 102 and subfloor components 106, having projections
104 and recesses 108, respectively, form mortise and tenon joints
and fit together in much the same way as wall webs 202 and wall
flanges 206. Similar to the components of wall system 200 described
above, each floor joist 102 and subfloor component 106 defines a
plane, and when projections 104 are received within recesses 108,
the planes defined by the floor joists 102 are perpendicular to the
planes defined by the subfloor components 106. Further, one of
ordinary skill in the art will appreciate that any appropriate
number of projections 104 and recesses 108 may be used to attach
subfloor components 106 and floor joists 102.
[0056] Turning to FIG. 9, roof 300 includes a plurality of roof web
components 302. Each roof web 302 has at least one projection 304,
which is a first connection geometry. Projections 304 have a
defined or particular shape for joining the components of roof 300,
as described herein. Further, roof 300 comprises a plurality of
roof flange components 306. Each roof flange 306 defines at least
one recess 308, which is a second connection geometry. Recesses 308
are configured for receipt of projections 304, i.e., the first
connection geometry joins with the second connection geometry to
connect adjacent roof webs 302 and roof flanges 306. For example,
in roof 300, at least one roof flange 306 is adjacent a roof web
302 such that a projection 304 of roof web 302 fits within a recess
308 of roof flange 306. As previously described, such an
arrangement forms mortise and tenon joints between attached webs
302 and flanges 306, which does not require mechanical fasteners to
attach the webs 302 to adjacent flanges 306. Similar to the
components of wall system 200 and floor system 100 described above,
each roof web 302 and roof flange 306 defines a plane, and when
projections 304 are received within recesses 308, the planes
defined by the roof webs 302 are perpendicular to the planes
defined by the roof flanges 306. Moreover, one of ordinary skill in
the art will appreciate that any appropriate number of projections
304 and recesses 308 may be used to attach webs 302 and flanges
306.
[0057] Referring still to FIG. 9, each roof web 302 has a first
edge 310 opposite a second edge 312 and a third edge 314 opposite a
fourth edge 316. More particularly, in the depicted embodiment,
first edge 310 and second edge 312 are spaced apart along a length
direction L and third edge 314 and fourth edge 316 are spaced apart
along a width direction W. Four projections 304 are defined along
third edge 314 and four projections 304 are defined along fourth
edge 316. Further, a first web 302a includes an extension 318 along
first edge 310, which defines projections 304 and other features
for attaching web 302 to wall system 200. A second web 302b defines
a feature or connection geometry along second edge 312 for
attaching web 302b to other features of roof 300. Each web 302
defines a plane P.sub.rw such that edges 312, 314, 316, 318 lie
within plane P.sub.rw.
[0058] Continuing with FIG. 9, first web 302a defines half of a
S-joint, described in greater detail below, along its second edge
312. Second web 302b defines another half of the S-joint along its
first edge 310. Connecting first web 302a and second web 302b at
adjacent S-joint halves to form a full S-joint, as shown in FIG. 9,
thereby extends the length of webs 302. Moreover, some webs 302,
such as second web 302b, define an aperture 320. Similar to
apertures 218 defined in wall webs 202, apertures 320 defined in
webs 320 can reduce a weight of webs 302 and also provide a space
or area through which building materials or elements, such as duct
work, wiring, plumbing, and the like, can be passed or
positioned.
[0059] As further shown in the exemplary embodiment of FIG. 9, each
roof flange 306 has a first edge 322 opposite a second edge 324 and
a third edge 326 opposite a fourth edge 328. First edge 322 and
second edge 324 are spaced apart along the length direction L and
third edge 326 and fourth edge 328 are spaced apart along the width
direction W. Flanges 306 define a plane P.sub.rf such that edges
322, 324, 326, 328 lie within plane P.sub.rf.
[0060] Roof system 300 is comprised of a plurality of rafters 330.
Each rafter 330 includes two flanges 306 and two webs 302
positioned side-by-side, where the webs 302 are formed from joined
first and second webs 302a, 302b. The adjacent webs 302 are
positioned side-by-side such that the adjacent S-joints are
oriented opposite one another, as shown in FIG. 9. Reversing the
orientation of the adjacent S-joints of webs 302 helps strengthen
rafters 330. Further, one flange 306 is positioned along third edge
314 of webs 302 and the other flange 306 is positioned along fourth
edge 316 of webs 302. The plane P.sub.rf defined by each flange 306
is oriented perpendicularly to plane P.sub.rw defined by webs 302.
Accordingly, projections 304 defined along third and fourth edges
314, 316 of web2 302 fit within recesses 308 of flanges 306 to
attach webs 302 and flanges 306. As such, mortise and tenon joints
are formed between attached webs 302 and flanges 306. One of
ordinary skill in the art will appreciate that any appropriate
number of projections 304 and recesses 308 may be used to attach
webs 302 and flanges 306 and that recesses 308 of flanges 306 may
be appropriately sized to receive two projections 304, one from
each of the adjacent webs 302.
[0061] FIGS. 10 and 11 illustrate roof webs 302 according to other
embodiments of the present subject matter. Similar to the roof webs
302 described with respect to FIG. 9, the roof web 302 depicted in
FIG. 10 comprises multiple webs, namely a first web 302a, a second
web 302b, and a third web 302c, and the roof web 302 depicted in
FIG. 11 comprises multiple webs, namely a first web 302a and a
second web 302b. However, rather than employing a S-joint to
connect adjacent webs 302a, 302b and 302b, 302c, the roof webs 302
of FIGS. 10 and 11 use dovetail joints DJ to connect adjacent webs.
Moreover, similar to the embodiment of FIG. 9, some webs 302, such
as second web 302b in FIG. 10 and each of the first web 302a and
the second web 302b in FIG. 11, define one or more apertures 320,
which may reduce a weight of webs 302 and also provide a space or
area through which building materials or elements, such as duct
work, wiring, plumbing, and the like, can be passed or positioned.
Further, each roof web 302 depicted in FIGS. 10 and 11 defines a
plurality of projections 304 for receipt in recesses 308 of roof
flanges 306 as previously described.
[0062] It will be readily understood that, like wall webs 202 and
wall flanges 206, floor joists 102, subfloor components 106, roof
webs 302, and roof flanges 306 may define notches and/or holes for
the receipt of ties that help hold joists 102 and subfloor
components 106 in place with respect to one another and to hold
webs 302 and flanges 306 in place with respect to each other. For
example, roof webs 302 may define notches n adjacent apertures 320
and/or holes h adjacent or near edges of webs 302, and roof flanges
306 may define notches n along their edges and/or holes h near or
adjacent the edges. Ties t may be received or positioned within
notches n and/or holes h to, when fastened, hold a web 302 and
flange 306 in place with respect to one another. Similarly, floor
joists 102 and subfloor components 106 may define notches n and/or
holes h. Ties t may be received or positioned within notches n
and/or holes h to, when fastened, hold a joist 102 and subfloor
component 106 in place with respect to one another. Any appropriate
number of notches n and/or holes h and ties t may be used to secure
during construction the components of floor 100 in place with
respect to one another, the components of wall 200 in place with
respect to one another, and the components of roof 300 in place
with respect to one another. It will also be appreciated that
various components of floor 100, wall 200, and roof 300 may define
notches n and/or holes h for the receipt of ties t to hold
components of floor 100 in place with respect to wall 200 and
components of wall 200 in place with respect to roof 300.
[0063] As such, ties t help the components of floor, wall, and roof
systems 100, 200, and 300 resist forces that would tend to cause
the components to slip or move with respect to one another during
construction. Therefore, ties t help hold the components in place
until the framing system or systems are structurally activated,
e.g., until all connected components engage with one another. The
connection geometries of the various components, rather than ties
t, connect the components and structurally lock them in place with
respect to one another once the system is structurally
activated.
[0064] Preferably, the components of floor, wall, and roof systems
100, 200, 300 (e.g., floor joists 102, subfloor components 106,
wall webs 202, wall flanges 206, roof webs 302, and roof flanges
306) are fabricated from standard sheets of plywood, e.g., four
foot by eight foot (4'.times.8') sheets of three-quarter inch
(3/4'') thick plywood. In exemplary embodiments, the shape of each
component, including protrusions 104, 204, 304 and recesses 108,
208, 308, is produced using a computer numerical control (CNC)
router. That is, control algorithms, also called cut files, are
written for each different component of the floor, wall, and/or
roof systems 100, 200, 300. As an example, wall 200 may include
several different shaped wall web components 202. In one
embodiment, wall 200 may include a wall web 202 having one
projection 204 defined along one edge and two projections 204
defined along another edge; another wall web 202 having two
projections 204 defined along each of two opposite edges; another
wall web 202 having three projections 204 defined along one edge
and two projections 204 defined along an opposite edge; and so on.
Cut files may be created for each type or version of wall web 202.
Then, when the components of wall 200 are fabricated, certain types
or versions of web 202 may be required in varying numbers for the
wall system 200, and the required cut files may be sent or
delivered to the CNC router for fabricating the required number of
each different version of wall web 202. Each additional component
of floor 100, wall 200, and/or roof 300 may be similarly
fabricated. That is, cut files may be generated for different
versions of each web, flange, joist, subfloor, or other component,
and the different versions required for a given floor 100, wall
200, and/or roof system 300 may be sent or delivered to a CNC
router for the fabrication of the required number of each version
of the component.
[0065] As such, the components of building framing system 10,
including the components of floor, wall, and roof systems 100, 200,
300, may be cut from at least one sheet of a building material such
as structural plywood such that each component has the needed
length and width, as well as the required connection geometry,
before being delivered to a construction site. That is, the
required connection geometry may be pre-cut into each component.
Further, each component may be numbered and/or labeled to improve
efficiency and accuracy in constructing floor, wall, and roof
systems 100, 200, 300. For example, the number or label for a given
component may be routed into the component, as shown in FIG. 4.
[0066] Moreover, it will be appreciated that, to standardize the
components and/or reduce the number of unique components,
connection geometry and/or other features may be included in a
component that is not needed for the actual end use of a given
component. For example, an aperture for an electrical outlet may be
included as part of, e.g., a template for a wall flange 206, but an
electrical outlet may not be installed in every electrical outlet
aperture. Reducing the number of unique components may reduce the
complexity of building framing system 10, as well as any of its
portions 100, 200, 300, which can improve efficiency and accuracy
in constructing building framing system 10.
[0067] Plywood sheathing, or structural plywood, is a preferred
material for fabricating the components of building framing system
10, including the components of floor 100, wall 200, and roof 300,
because of the strength of structural plywood in view of its
availability, cost, weight, and environmental impact. More
particularly, structural plywood typically is a highly standardized
industrial product made from laminated sheets or layers of wood
veneer, where the wood grain of adjacent layers is rotated such
that the wood grain alternates directions from one layer to the
next. Alternating the grain direction of the layers enhances the
dimensional stability of plywood, i.e., where wood tends to shrink
or swell in its radial and tangential grain directions, the
alternating grain directions of plywood balances and minimizes
shrinkage, swelling, and warping. Also, structural plywood is
inherently devoid of knots and other inconsistencies common in
typical lumber boards because care is taken in the plywood
manufacturing process to avoid the alignment of knots from one
layer or ply to the next. Moreover, the geometries or shapes needed
for each component of floor 100, wall 200, and roof 300--e.g., the
shape of each projection 104, 204, 304 and recess 108, 208,
308--can be cut from structural plywood using a CNC router as
described while maintaining the integrity of the plywood. As a
result, plywood offers several advantages--economy, accessibility,
ease of use, and strength--but it will be readily understood that
other materials also may be used to fabricate the components of
floor 100, walls 200, and roof 300. For example, other materials
may be more readily available or better suited to a particular use
of building framing system 10 and/or its portions 100, 200,
300.
[0068] Although described above with respect to a particular type
of connection geometry--generally, a mortise and tenon joint formed
between projections 104, 204, 304 and recesses 108, 208, 308--floor
100, wall 200, and roof 300 may use other types of connections or
connection geometries as well. Referring now to FIGS. 12-28,
additional types of connection geometries and/or component
geometries are illustrated. It will be appreciated that, while
certain connections and component geometries are described herein,
other connections and component geometries may also be within the
spirit and scope of the present subject matter and also may be used
in building framing system 10, including floor, wall, roof systems
100, 200, 300.
[0069] Referring particularly to FIG. 12, one embodiment of a
mortise and tenon double field connection DFC is depicted. In some
embodiments of the framing systems described herein, two webs may
be used side-by-side, e.g., to strengthen a portion of the frame or
to provide support for a feature of the system. As an example, two
wall webs 202 may be positioned side-by-side, with each web 202
defining a projection 204 that is adjacent the projection 204 of
the adjacent web 202, as shown in FIG. 12. A wall flange 206
positioned adjacent the double web 202 must define a recess 208
sufficiently large to receive the two projections 204. The double
field connection DFC may be used, e.g., in wall studs and roof
rafters, such as studs 228 and rafters 330 described herein.
[0070] FIG. 13 illustrates a mortise and tenon header connection
HC, primarily used in web-to-flange connections. As shown in FIG.
13, the recess of the flange is sufficiently large to receive
multiple web projections. The mortise and tenon header connection
HC may be located at or between wall studs 228 and roof rafters
330.
[0071] Referring now to FIG. 14, one embodiment of a mortise and
tenon standard edge connection SEC is depicted. It will be readily
appreciated that, in some portions of the framing systems described
herein, a user may desire to join framing components at right
angles to each other in a manner different from the web-to-flange
connections described above and shown, e.g., in FIGS. 4, 7A, and
7B, where the edges of flanges 206 extend to either side of web
202. As illustrated in FIG. 14, in the standard edge connection, a
web projection fits within a flange recess such that the edge of
the web having the projection is positioned adjacent the edge of
the flange defining the recess. As such, the depicted edge
connection SEC may be used in web-to-flange connections but also
may be used in box connections, and the edge connection SEC
generally may be located in wall studs, roof rafters, and floor
joists.
[0072] Turning to FIG. 15, one embodiment of a slot connection SC
is shown. Slot connections SC may be used in perpendicular
surface-to-surface connections. For example, as illustrated, a
first component c.sub.1 may define a slot s into which is received
a second component c.sub.2 that is oriented perpendicular to the
first component c.sub.1. Slot connections SC generally may be
located at roof rafters, floor joists, and box girders.
[0073] FIG. 16 illustrates one embodiment of a single notch
connection SNC. As shown, projections may fit within recesses of
adjacent flanges to join the adjacent flanges. As such, the single
notch connection SNC primarily may be used in flange-to-flange
connections, as well as box connections. Single notch connections
SNC generally are located at edge flanges and window boxes.
[0074] FIG. 17 provides one embodiment of a double notch connection
DNC. Double notch connections DNC primarily may be used in nogging
connections in floor 100, which are described in more detail below.
As illustrated in FIG. 17, floor nogging 110 defines a double notch
to connection adjacent floor joists 102, which are positioned
end-to-end. Accordingly, double notch connections DNC may most
commonly be located at floor 100, between floor nogging 110 and
joists 102.
[0075] Referring now to FIG. 18, one embodiment of a S-joint
connection SJC is illustrated. As previously described, S-joint
connections SJC may be used to connect co-planar components such as
roof webs 302. In exemplary embodiments, one half of the S-joint is
defined by a first component c.sub.1 and the other half of the
S-joint is defined by a second component c.sub.2. The two halves of
the S-joint are joined together to join or attach the adjacent
components c.sub.1, c.sub.2 end-to-end. S-joint connections SJC
typically may be used as web-to-web or flange-to-flange
connections, for connecting co-planar adjacent webs and co-planar
adjacent flanges. Further, S-joint connections SJC generally may be
located at roof rafters and leveling joists.
[0076] FIG. 19 depicts one embodiment of a Z-joint connection ZJC.
Z-joint connections ZJC may be used in horizontal web-to-web
connections. For example, Z-joint connections ZJC may be used to
join adjacent webs in wall headers. In exemplary embodiments, such
as the embodiment shown in FIG. 19, one half of the Z-joint is
defined by a first component c.sub.1 and the other half of the
Z-joint is defined by a second component c.sub.2. The two halves of
the Z-joint are joined together to join or attach the adjacent
components c.sub.1, c.sub.2 end-to-end.
[0077] Turning to FIG. 20, an illustration of one embodiment of a
tilt-up wall connection TWC is provided. The tilt-up wall
connection TWC is a horizontal-to-vertical connection primarily
used to connect wall studs to floor joists. The rounded shape of
the joint helps a wall section, which generally will comprise a
plurality of studs 228 and other wall components, be tilted up and
joined into place with respect to floor 100.
[0078] FIGS. 21 and 22 illustrate one embodiment of a ball joint
connection BJC. Ball joint connections BJC generally connect outer
wall flanges 206b to a perimeter or rim joist 112 of floor 100,
described in greater detail below. As shown most clearly in FIG.
21, outer flange 206b has a rounded tab 234 that fits within a
cut-out 114 defined in rim joist 112. Such ball joint connections
BJC provide resistance against uplift forces, e.g., caused by high
winds or earthquakes. Further, the depicted ball joint connection
BJC used in combination with the tilt-up wall connection TWC
depicted in FIG. 20 helps the walls of wall system 200 securely
stand on their own, without requiring temporary bracing to keep the
walls in place with respect to floor 100 and to prevent the walls
from tilting or falling.
[0079] FIGS. 23-25 illustrate a blunt tooth connection BTC between
framing system components, as well as a double notch connection DNC
as described with respect to FIG. 17. As shown in FIGS. 23 and 24,
blunt tooth connections BTC may be used between brace members 236,
which reinforce sections of wall system 200, and wall components
such as wall studs 228, floor components such as rim joists 112,
and/or roof components such as rafters 330. In the embodiments
illustrated in FIGS. 23 and 24, the brace members 236 extend
between components generally at an angle .alpha. with respect to
the horizontal direction H such that the brace members 236
generally extend at an angle with respect to other wall components.
The angle .alpha. may be within a range of about 30.degree. to
about 60.degree., and in some embodiments, the angle .alpha. may be
approximately 45.degree.. Of course, other values of the angle
.alpha. may be used as well.
[0080] Further, referring particularly to FIG. 24, the blunt tooth
connection BTC also may be used at ends of brace members 236 to
connect the brace members 236 to one another. Further, a double
notch connection DNC may be defined at or near the blunt tooth
connection BTC to connect the brace members 236 to components that
are perpendicular widthwise to the brace members 236, e.g., to
connect the brace members 236 to an edge 210, 212, 214, 216 of a
wall web 202 or an edge 220, 222, 224, 226 of a wall flange 206.
For instance, as illustrated in FIG. 25, a blunt tooth connection
BTC may be used to connect two brace members 236 end-to-end, and a
double notch connection in the area of the blunt tooth connection
BTC connects the brace members 236 to an edge of two joined wall
webs 202.
[0081] Turning to FIGS. 26 through 28, an illustration is provided
of embodiments of a step joint SJ. The step joint SJ is an
end-to-end connection primarily used to connect wall webs 202, as
shown in FIG. 26, or a wall web 202 and a roof web 302, as shown in
FIGS. 27 and 28. Referring to FIGS. 25 and 26, the wall webs 202
also may define one or more notches or recesses 238 near the step
joint SJ, e.g., for forming the double notch connection DNC between
the joined wall webs 202 and the brace members 236 and/or for
receipt of a connector 20 that helps connect the wall webs 202 to
one another. FIGS. 27 and 28 illustrate a step joint SJ or step end
connection between an end of a wall web 202 and an end of a roof
web 302. As shown in FIG. 27, roof brace members 336 may be used,
e.g., to help reinforce sections of roof system 300, and similar to
wall brace members 236 illustrated in FIGS. 23 and 24, the roof
brace members 336 may extend at angle with respect to other roof
components. Additionally, as most clearly illustrated in FIG. 28, a
key 30 inserted in apertures 32 defined by the wall web 202 and
roof web 302 helps connect the wall and roof components.
[0082] Referring now to FIGS. 29, 30, and 31, additional details of
floor framing system 100 will be described in more detail. FIG. 29
illustrates a floor joist connection FJC for connecting adjacent
floor joists 102. As depicted in FIG. 29, a connector 40 spans the
interface between adjacent ends 102a and 102b of the adjacent floor
joists 102. The connector 40 generally comprises two truncated
triangular portions 42 that are connected by a connection portion
44. Each triangular portion 42 fits within or is received within a
complementary shaped recess in a respective floor joist end 102a,
102b. The connection portion 44 spans the interface between the
floor joist ends 102a, 102b. Further, a plurality of holes h may be
defined in each of the connector 40 and first and second ends 102a,
102b, and as previously described, a tie t may be passed through
adjacent holes h and fastened to secure the connector 40 to the
floor joist 102.
[0083] As shown in FIG. 30, in addition to floor joists 102
describe above, floor 100 may also include one or more leveling
joists 116. Leveling joists 116 are positioned perpendicular to
joists 102, and joists 102, 116 may be connected using a slot
connection SC as described above with respect to FIG. 15. Further,
floor nogging 110 may be connected to joists 102 using the double
notch connection DNC described above with respect to FIG. 17. As
shown, holes h may be defined in joists 102 and nogging 110 and
ties t passed through holes h and fastened together to hold joists
102 and nogging 110 in place with respect to one another during
construction of floor 100 and any additional systems, such as wall
system 200 and roof system 300. As illustrated in FIG. 31, floor
100 further may include a plurality of small joists 118, end joists
120, and floor plates 122, as well as rim joists 112 as previously
described. As shown, end joists 120 define a portion of the tilt-up
wall connection joint TWC described with respect to FIG. 20.
[0084] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they include structural elements that do not
differ from the literal language of the claims or if they include
equivalent structural elements with insubstantial differences from
the literal language of the claims.
* * * * *